Light emissive plastic glazing

ABSTRACT

A window assembly having a first transparent area and a light emissive area. The panel includes a first transparent layer with an ultraviolet blocking layer and an abrasion layer. The light emissive area includes a light emissive layer that may be an organic light emitting display, an electroluminescent display, a polymer light emitting display or a light pipe configured to receive light from a light source.

RELATED APPLICATION

This application claims the benefit of U.S. provisional applicationentitled “LIGHT EMISSIVE PLASTIC GLAZING”, application number,60/663,237 filed on Mar. 18, 2005.

BACKGROUND

1. Field of the Invention

The present invention generally relates to vehicle occupant compartmentlighting systems

2. Description of the known Technology

The occupant compartment of a vehicle, more particularly an automobile,typically uses one or more lighting system to provide general lightingto the occupant compartment of the vehicle. This lighting enhances thevisibility of areas within the occupant compartment that are notprovided with their own lighting, such as areas occupied by occupantsand their belongings, the center console and vehicle controls. Thelighting system that provides general visibility to the occupantcompartment is usually placed within the compartment such that the lightit produces illuminates as much of the occupant compartment as possible,while taking up the least amount of space. One such lighting system,also called a “dome light”, is located near the center of the roof ofthe occupant compartment.

Automobiles can be equipped with transparent rectangular panels locatednear the center of the roof, commonly referred to as a “sunroof” or“moon roof”. As stated earlier, the center location of the roof is thepreferable position for the dome light. When a vehicle has a sunroof,the dome light must be moved to a less favorable location or eliminated,thus, reducing or eliminating effective general illumination of theoccupant compartment.

Therefore, it is desired to provide a system which will provide adequateillumination of the occupant compartment of vehicles equipped withsunroofs.

BRIEF SUMMARY

In overcoming the drawbacks and limitations of the know technologies, alight emissive window assembly is disclosed. The assembly includes afirst transparent layer and light emissive layer coupled to the firsttransparent layer. The first transparent layer is made from a suitablematerial such as polycarbonate, polymethyl methacrylate, polyesterblends or glass fibers or combinations thereof. The first transparentlayer may further include an ultraviolet (“UV”) blocking layer and/or anabrasion layer.

The light emissive layer may be a multistack of functionalities and canbe applied directly using conventional printing technologies such asinkjet, screen printing, dispensing and sputtering or any other suitablemethod. A more preferable manufacturer would be a multilayer film. Themultilayer film may be an electroluminescent display, organic lightemitting display, a polymer light emitting display, or may be a lightpipe having an entry point for receiving light generated by a lightsource, whereby light received at the entry point will travel within thelight pipe via total internal reflection.

Additionally, a second transparent layer may be coupled to the emissivelayer, thereby capsulating the emissive layer between the twotransparent panels. The second transparent panel is constructedsimilarly to the first transparent panel and may have an abrasion layerand/or a UV blocking layer. The window assembly may be made by firstforming a transparent panel having one side coated with an ultravioletblocking layer and an abrasion layer. Next, a frame is formed around apotion of the perimeter of the plastic panel, thereby defining a cavity.A light source, such as the previously mentioned emissive layer, isplaced within the cavity and bonded to the first transparent panel. Asecond transparent panel is thereafter attached to the frame and/or thefirst transparent panel, thereby encapsulating the light source.

These and other aspects and advantages of the present invention willbecome apparent upon reading the following detailed description of theinvention in combination with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an automobile having a light emittingwindow assembly embodying the principles of the present invention;

FIG. 2 is a top view of the window assembly embodying the principles ofthe present invention;

FIG. 3 is a top view of another embodiment of the window assemblyembodying the principles of the present invention;

FIG. 4A is cross sectional view of a portion of the window assemblygenerally taken along lines 4-4 in FIG. 2;

FIG. 4B is a cross sectional view similar to FIG. 4A of a windowassembly using a polymer light emitting display;

FIG. 4C is a cross sectional view similar to FIG. 4A of the windowassembly of the window assembly using a polymer light emitting displayas the emissive layer and a conductive ink;

FIG. 4D is a cross sectional view of a window assembly using a PLED asthe emissive layer;

FIG. 4E is a cross sectional view similar to FIG. 4A of a windowassembly made using a two shot process and embodying the principles ofthe present invention;

FIG. 5 is a top view of another embodiment of the window assemblyembodying the principles of present invention;

FIG. 5A is a cross sectional view of a portion of the window assemblygenerally taken and lines 5A-5A in FIG. 5;

FIG. 6 is a side view of the window assembly shown in FIG. 5; and

FIG. 6A is a cross sectional view of a portion of the light emissivelayer generally taken along lines 6A-6A of FIG. 6.

DETAILED DESCRIPTION

Referring to FIG. 1, an automobile 10 incorporating the presentinvention is shown therein. The automobile 10 includes an occupantcompartment 12 located within the interior of the automobile 10 and awindow assembly 14 mounted via a frame 16 to the automobile 10. As willbe fully described in the following, the window assembly 14 providesillumination to the occupant compartment 12 as indicated by the arrowsreferenced by the numeral 18.

Although this description describes using the panel 14 as a sunroof ormoonroof to provide illumination to the occupant compartment 12 of theautomobile 10, the invention is equally applicable to other areas of theautomobile 10. For example, the panel 14 may be appropriately locatedand dimensioned to provide the lighting requirements for a headlight,taillight, turn signal, brake light, instrument panel light, reverselight or any other light commonly found on automobiles.

Referring to FIG. 2, a more detailed view of the window assembly 14 isshown. As shown therein, the window assembly 14 has a transparentviewing area 20 and an emissive area 22. The emissive area 22 is theportion of the window assembly 14 which emits light that illuminates theoccupant compartment. The transparent area 20 is similar to aconventional window assembly in that the transparent area 20 does notemit light. Similar to the transparent area 20, the emissive area 22 maybe transparent, but may alternatively be opaque. Also, variousconfigurations for the layout of the emissive area 22 and transparentareas 20 can be envisioned, configurations other than a single centraltransparent area 20 encircled by an emissive area 22.

Another embodiment of the window assembly 14 is shown in FIG. 3. In thislayout, the window assembly 14 has two transparent areas 24, 26surrounded and separated by an emissive area 28. Similar to the previousembodiment, the transparent area 24 is similar to a conventional windowassembly, while the emissive area 28 is capable of emitting light.Obviously, the emissive area 28 may be laid out as desired in any numberof patterns.

Referring to FIG. 4A, a cross section, generally taken along lines 4-4in FIG. 2 is shown therein. The emissive area 22 includes a firsttransparent panel 32 and second transparent panel 34 and between whichis located the emissive element. The first transparent panel preferablyincludes an abrasion layer 36 and a UV blocking layer 38 provided over abase layer 40. The base layer 40 may be made of polycarbonate,polymethyl methacrylate, polyester blends, glass and glass fibers or anycombination thereof. The UV blocking layer 38 may have dispersed UVabsorbing additives.

The second transparent layer includes a UV blocking layer 42 and anabrasion layer 44. Similar to the first transparent panel 32, the UVblocking layer 42 of the second transparent panel 34 may have dispersedUV absorbing additives.

Coupled to the base layer 40 of the first transparent panel 32 may be ablack out ink layer 46. The black out ink layer prevents any lightentering the first transparent panel 32 from reaching the secondtransparent panel 34. Alternatively, the portion 30 may not have theblack out ink layer 46.

Located between the first and second transparent panels 32, 34 is anemissive layer 52. The emissive layer 52 may be one of a variety of suchlight emitting structures, including, without limitation, a polymerlight emitting display (“PLED”), an organic light emitting display(“OLED”), a light emitting diode (“LED”) used in conjunction with alight pipe to direct light emitted by the LED to the emissive area 22 ofthe panel 14 or, as shown in this embodiment, an electroluminescentdisplay (“ELD”). The emissive layer 52 includes a dielectric layer 54and a phosphor layer 56 connected to a high conductive material the lowconductive material 50, respectively.

The light emissive layer 52 can be placed onto the surface of the baselayer 40 or black-out ink 46, thereby, being protected from bothabrasion and UV light as this is desirable for enhancing the functioningand lifetime of the device. The light emissive layer 52 mayalternatively be applied directly to the abrasive layer 36, as well asin between any existing protective layers. The light emissive layer 52can be printed or applied by such technologies as screen printing, inkjet printing and sputtering, among others. Such printing may beperformed either before or after shape forming of the window 14 or thepanels 32, 34. In addition, the light emissive layer 52 can be appliedto a thin polymer films by any means known to those skilled in the art,with subsequent application to the base layer 40 via film insert molding(“FIM”) or lamination techniques. It may be desirable to have additionaltransparent layers to protect the light emissive layers during the FIMprocess.

A voltage source 58 is connected between the high conductive material 48and the low conductive material 50, thereby providing a current throughthe dielectric 54 and the phosphor 56. When a sufficient current isprovided through the dielectric 54 and the phosphor 56, light, asindicated by the arrows 60 is emitted by the emissive layer 52, betweenthe overlying portions of the high conductive material 48 and the lowconductive material 58, and is passed through the UV blocking layer 42and the abrasion layer 44 of the second transparent panel 34.

Referring to the schematic representation of FIG. 4B, a PLED is used asthe emissive layer 52. PLED's are typically used for backlighting andillumination, as well as the creation of displays. By definition,polymers are substances formed by a chemical reaction in which two ormore molecules form into larger molecules. PLED's represent thin filmdisplays that are created by sandwiching an undoped conjugated polymerbetween two proper electrodes at a very short distance.

The manufacturing of PLEDs comprises a unique deposition sequence. Thissequence includes the following steps: 1) forming the structuredtransparent conductive oxide (e.g., indium tin oxide, etc.) anode; 2)inkjet printing the layer which will inject P-charge carriers; 3) inkjetprinting of the PLED layer; 4) curing to evaporate the solventsnecessary for the printing (e.g., about 98% solvents & 2% solidcontent); 5) deposition of the cathode by metal evaporation (Ba/Ca, thenAl); and 6) encapsulation by depositing transparent layers (e. g.combination of SiN_(x) and a scratch-resistant coating) For example, theabove steps in this process cannot be performed out of sequence or inthe reverse manner. Starting the steps with the cathode (Ba—Al) is notpossible because barium is very sensitive to the solvents necessary forthe inkjet printing of the PLED material.

The emissive layer 52 includes an emissive polymer 62 such aspolyphenylene vynylene (“PPV”) or polyflourene, and a conductive polymer64 such as polydioctyl-bithiophene or polyaniline. Sandwiching theemissive polymer 62 and the conductive polymer 64 are a cathode 66 andan anode 68. To provide support, a substrate 70 is located beneath theanode 68.

As a consequence of this deposition process, the emission of light froma PLED is always in the direction that goes through the transparentsubstrate. This means that in order to use a PLED to illuminate avehicle by depositing or printing the PLED directly onto a transparentplastic substrate, the PLED will need to be on the outside of thevehicle where it will be difficult to protect from environmentaldegradation.

In order to have the illumination projected into the vehicle, theintegration of the PLED into the window/roof assembly from the insidewith an adhesive is preferred and is shown in FIG. 4C. One type ofadhesive system available for this type of process includes hot meltbonding.

Referring to FIG. 4C, the PLED is shown integrated into the windowassembly 14. Similar to FIG. 4A, the window assembly 14 has a first andsecond abrasion layer 36, 44 each coupled to a first and second UVblocking layer 38, 42. Beneath the other UV blocking layer is a baselayer, such as a polycarbonate panel 40. Painted onto the polycarbonatepanel 40 is a black-out ink layer 46. Coupled between the black-out inklayer 46 and the second UV blocking layer 42 are the cathode 66 andanode 68, respectively. Between the cathode 66 and anode 68 is theemissive layer 52 having the emissive polymer layer 62 and theconductive polymer layer 64. The voltage source 58 provides a currentthrough the cathode and anode 68. When a sufficient current passesthrough the emissive layer 52, the emissive layer 52 will produce alight indicated by the arrows referenced by numeral 74.

In the embodiments of either FIGS. 4B or 4D, when a voltage source 58provides a sufficient current through the emissive polymer layer 62 andthe conductive polymer 64 layer via the cathode 66 and anode 68, theemissive polymer layer 62 will emit light, as denoted by the arrowsdesignated at 74.

Referring to FIG. 4D, another embodiment of a PLED light emissive layer52 is shown. In this embodiment, the anode 68 is constructive of ametallic paste or ink, such as a silver ink sold under the trademarkParamod by Paralec Incorporated. The ink 68 is arranged in a gridpattern defining holes 76. The holes 76 allow for various degrees ofillumination in areas in which the conductor is not present. Themetallic paste or ink may be also utilized when using OLED's, ELD's orLED's as the emissive layer.

Referring to FIG. 4E, another schematic representation of the emissivearea 22 of the window assembly 14 is shown. The window assembly 14includes a base layer 80 (a polycarbonate or other material layer) asthe first shot in a two component molding process. A colored frame 82 iscoupled to the polycarbonate layer 14 by a second molding shot in thetwo component molding process. The molding of the colored frame 82 canbe done in such a way as to form a recess cavity 84 in the frame. Anemissive lighting system 86 such as a PLED, OLED, ELD, or LED emissivelayer is therefore located within the cavity 84. To enclose the cavityand protect the emissive lighting system 86 is a polycarbonate plug 88.The polycarbonate plug may be attached to the cavity by an adhesive 90,frictional engagement or other suitable fashion, and along with the baselayer 80, may be coated with an UV protection layer and an abrasionlayer.

An electrical contact 91, such as a conductive wire, having a first end93 and a second end 95 is situated between the plug 88 and the frame 82such that the first end 93 of electrical contact 91 is in electricalcommunication with the emissive lighting system 86. A power supply (notshown) is connected to the second end 95 of the electrical contact. Whenthe power supply provides a sufficient current to the lighting system86, the lighting system 86 will emit light through the plug 88 asindicated by arrows 97.

It is possible to eliminate the additional UV protection layer. Forexample, the exterior of the base layer 40 may be coated with theExatec® 900 Glazing system sold by Exatec, LLC of Michigan, and on theinside with only a “glass-like” coating deposited by plasma enhancedchemical vapour deposition (“PECVD”) or other processes known to thoseskilled in the art. The PLED may be separately formed on a transparentpolycarbonate film or substrate, which can be subsequently coated withthe “glass-like” coating. The embodiment above offers the advantage thatthe coating process for the PLED is separate from the coating processfor the window assembly 14. Moreover, the process of making the PLED canbe technically and economically optimized independent of the windowassembly 14 coating process.

Referring to FIG. 5, a more detailed view of another embodiment of thewindow assembly 14 is shown. As shown therein, the window assembly 14has a transparent viewing area 20. Located within the transparent viewarea 20 are multiple light emissive areas 102, 104, 106. Surrounding thewindow assembly 14 is a frame 114. As will be explained later, the frame114 contains one or more light sources for providing illumination to theemissive areas 102, 104, 106.

Referring to FIG. 5A, a cross section, generally taken along lines 5A-5Ain FIG. 5 is shown therein. The window assembly 14 includes apolycarbonate layer 116 coupled to a polymethyl methcrylate (“PMMA”)layer 118. Preferably, a FIM technique is used to couple thepolycarbonate layer 116 to the PMMA layer 118. Define between the PMMAlayer 118 and the polycarbonate layer 116 are the emissive areas 102,104, 106. These emissive areas are formed within the PMMA layer 118 andare enclosed by the polycarbonate layer 116 when the PMMA layer 118 iscoupled to the polycarbonate layer 116. Similar to FIG. 4A, the windowassembly 14 has a first and second abrasion layer 36, 44 each coupled toa first and second UV blocking layer 38, 42.

Referring to FIGS. 6 and 6A, a side view of the window assembly 14 and across sectional view of the window assembly 14 generally taken alonglines 6A-6A of FIG. 6 are shown. As described previously, the windowassembly 14 includes light emissive areas (light pipes) 102, 104, 106.The light emissive areas 102, 104, 106 are flanked by portions of thePMMA layer 118. In this embodiment, the PMMA layer 118 could be replacedwith other suitable materials. Located at end of the window assembly 14is the frame 114. Within the frame 114 are LEDs 120, 122, 124. Whenactivated, the LEDs 120, 122, 124, will emit light that will travelwithin the light emissive areas 102, 104, 106, via total internalreflection, with the exception that light traveling within the lightemissive areas 102, 104, 106 will emit light through the polycarbonatelayer 116, the UV blocking layer 42 and the abrasion layer 44, asdenoted by the arrows designated at 74. Alternatively, any light source,such as an electroluminescent display, an organic light emitting diodeand a polymer light emitting diode, may be used as light source.

Inasmuch as the foregoing disclosure is intended to enable one skilledin the pertinent art to practice the instant invention, it should not beconstrued to be limited thereby but should be construed to include suchaforementioned obvious variations and be limited only by the spirit andscope of the following claims.

1. A window panel assembly comprising: a first transparent layer havinga light emissive area and a transparent area; a light emissive layerlocated in the light emissive area and being supported by the firsttransparent layer; and the light emissive layer being configured toproduce and emit light therefrom.
 2. The assembly of claim 1, whereinthe first transparent layer is made from at least one of apolycarbonate, polymethyl methacrylate, polyester blends, glass fibers,glass and combinations thereof.
 3. The assembly of claim 1, wherein thefirst transparent layer includes an ultraviolet blocking layer and anabrasion layer.
 4. The assembly of claim 3, wherein the ultravioletblocking layer has dispersed ultraviolet absorbing properties.
 5. Theassembly of claim 1, wherein the assembly further comprises a secondtransparent layer coupled to the light emissive layer.
 6. The assemblyof claim 5, wherein the second transparent layer is made from at leastone of a polycarbonate, polymethyl methacrylate, polyester blends, glassfibers, glass and combinations thereof.
 7. The assembly of claim 5,wherein the second transparent layer further comprises an ultravioletblocking layer.
 8. The assembly of claim 5 wherein the second layerfurther comprises an abrasion layer.
 9. The assembly of claim 1, whereinthe light emissive layer is a multi-layered film.
 10. The assembly ofclaim 9, wherein the multi-layered film is an electroluminescentdisplay.
 11. The assembly of claim 9, wherein the multi-layered film isan organic light emitting display.
 12. The assembly of claim 9, whereinthe multi-layered film is a polymer light emitting display.
 13. Theassembly of claim 9, further comprising a conductive layer in electricalcommunication with the multi-layered film.
 14. The assembly of claim 13wherein the conductive layer is made of a conductive ink.
 15. Theassembly of claim 14, wherein the conductive ink is made of is a silverink.
 16. The assembly of claim 13, wherein the conductive layer is aconductive wire.
 17. The assembly of claim 13 wherein the conductivelayer is arranged in a grid pattern.
 18. The assembly of claim 13,wherein the conductive layer further comprises an opaque conductivelayer and a grid patterned conductive layer.
 19. The assembly of claim1, wherein the light emissive layer is a light pipe having an entrypoint for receiving light generated by a light source, whereby lightreceived at the entry point will travel within the light pipe via totalinternal reflection.
 20. The assembly of claim 19, wherein the lightsource is a light emitting diode.
 21. The assembly of claim 20, whereinthe light source is an electroluminescent display.
 22. The assembly ofclaim 20, wherein the light source is an organic light emitting diode.23. The assembly of claim 20, wherein the light source is a polymerlight emitting diode.
 24. The assembly of claim 1, further comprising aframe coupled to the perimeter of the first transparent panel.
 25. Anautomotive vehicle comprising portions defining an occupant compartmenthaving at least one window assembly; the window assembly a firsttransparent panel having a transparent viewing area and a light emissivearea; a first transparent layer having ultraviolet blocking layer and anabrasion layer; and the light emissive area including a light emissivelayer coupled to the first transparent layer, the emissive layer beingconfigured to emit light to the occupant compartment of the vehicle. 26.The vehicle of claim 25, wherein the first transparent layer is madefrom at least one of polycarbonate, polymethyl methacrylate, polyesterblends, glass fibers, glass and combinations thereof.
 27. The vehicle ofclaim 25, wherein the ultraviolet blocking layer has dispersedultraviolet absorbing properties.
 28. The vehicle of claim 25, whereinthe assembly further comprises a second transparent layer coupled to thelight emissive layer.
 29. The vehicle of claim 28, wherein the secondtransparent layer is made from at least one of polycarbonate, polymethylmethacrylate, polyester blends and glass fibers, glass and combinationsthereof.
 30. The vehicle of claim 28, wherein the second transparentlayer further comprises an ultraviolet blocking layer.
 31. The vehicleof claim 28, wherein the second layer further comprises an abrasionlayer.
 32. The vehicle of claim 25, wherein the light emissive layer isa multi-layered film.
 33. The vehicle of claim 32, wherein themulti-layered film is an electroluminescent display.
 34. The vehicle ofclaim 32, wherein the multi-layered film is an organic light emittingdiode.
 35. The vehicle of claim 32, wherein the multi-layered film is apolymer light emitting diode.
 36. The vehicle of claim 32, furthercomprising a conductive layer in electrical communication with themulti-layered film.
 37. The vehicle of claim 36, wherein the conductivelayer is made of a conductive ink.
 38. The vehicle of claim 37, whereinthe conductive ink is made of is a silver ink commonly sold under thetrademark Parmod from Paralec Incorporated.
 39. The vehicle of claim 36,wherein the conductive layer is a conductive wire.
 40. The vehicle ofclaim 36, wherein the conductive layer is arranged in a grid pattern.41. The vehicle of claim 37, wherein the conductive layer furthercomprises an opaque conductive layer and a grid patterned conductivelayer.
 42. The vehicle of claim 26, wherein the emissive layer is alight pipe having an entry point for receiving light generated by alight source, whereby light received at the entry point will travelwithin the light pipe via total internal reflection.
 43. The vehicle ofclaim 42, wherein the light source is a light emitting diode.
 44. Thevehicle of claim 42, wherein the light source is an electroluminescentdisplay.
 45. The vehicle of claim 42, wherein the light source is anorganic light emitting diode.
 46. The vehicle of claim 42, wherein thelight source is a polymer light emitting diode.
 47. A method for makinga window assembly comprising the steps of: forming a transparent panelhaving a first side and a second side; coating at least one of the firstside and the second side with a UV blocking layer; coating at least oneof the first side and the second side with an abrasion layer; forming aframe around a portion of the perimeter of the panel, the frame havingportions defining a cavity therein; and placing a light source withinthe cavity.
 48. The method of claim 45, further comprising the step ofattaching a cover over the cavity, thereby encapsulating the lightsource within the cavity.
 49. The method of claim 48, further comprisingthe step of placing an adhesive between the frame and the cover to bondthe cover to the frame.
 50. The method of claim 47, further comprisingthe step of attaching an electrical contact to the light source.